U.S. patent application number 14/571399 was filed with the patent office on 2015-07-09 for systems and methods for airfoil assembly.
The applicant listed for this patent is United Technologies Corporation. Invention is credited to Micah Beckman, Thomas J. Horn, Osamuyimen A. Oyegun, Michael Parkin, Joseph Rios.
Application Number | 20150190893 14/571399 |
Document ID | / |
Family ID | 53494503 |
Filed Date | 2015-07-09 |
United States Patent
Application |
20150190893 |
Kind Code |
A1 |
Parkin; Michael ; et
al. |
July 9, 2015 |
SYSTEMS AND METHODS FOR AIRFOIL ASSEMBLY
Abstract
A method for assembling an airfoil includes pressing a blade
body together with at least one of a blade sheath and a blade cover
between a plunger and a die base to join the blade body to the
blade sheath and/or the blade cover. The method can include
transferring heat from the plunger and/or the die base to at least
one of the blade body, the blade sheath and the blade cover to cure
an adhesive.
Inventors: |
Parkin; Michael; (South
Glastonbury, CT) ; Oyegun; Osamuyimen A.;
(Middletown, CT) ; Rios; Joseph; (Meriden, CT)
; Horn; Thomas J.; (Wallingford, CT) ; Beckman;
Micah; (Middletown, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
United Technologies Corporation |
Hartford |
CT |
US |
|
|
Family ID: |
53494503 |
Appl. No.: |
14/571399 |
Filed: |
December 16, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61923265 |
Jan 3, 2014 |
|
|
|
Current U.S.
Class: |
416/224 ;
29/889.71 |
Current CPC
Class: |
B23P 15/04 20130101;
F01D 5/282 20130101; Y10T 29/49337 20150115; F05D 2230/23 20130101;
F01D 5/147 20130101; B21D 53/78 20130101 |
International
Class: |
B23P 15/04 20060101
B23P015/04; F01D 5/28 20060101 F01D005/28 |
Claims
1. A method for assembling an airfoil comprising: pressing a blade
body together with at least one of a blade sheath and a blade cover
between a plunger and a die base to join the blade body to at least
one of the blade sheath and the blade cover.
2. A method as recited in claim 1, further comprising: transferring
heat from at least one of the plunger and the die base to at least
one of the blade body, the blade sheath and the blade cover to cure
an adhesive.
3. A method as recited in claim 2, wherein transferring heat from
at least one of the plunger and the die base includes transferring
heat through conduction.
4. A method as recited in claim 2, further comprising: applying an
adhesive between a broad side of the blade body at least one of the
blade cover and the blade sheath; and curing the adhesive with heat
transferred from at least one of the plunger and the die base.
5. A method as recited in claim 2, further comprising: applying an
adhesive between a leading edge of the blade body at least one of
the blade cover and the blade sheath; and curing the adhesive with
heat transferred from at least one of the plunger and the die
base.
6. A method as recited in claim 1, further comprising: positioning
a compliant layer between a broad side of the blade body and the
plunger, wherein the compliant layer is configured to substantially
equalize the distribution of pressure applied by the plunger across
the broad side of the blade body.
7. A method as recited in claim 1, further comprising: positioning
a compliant layer between a broad side of the blade body and the
die base, wherein the compliant layer is configured to
substantially equalize the distribution of pressure across the
broad side of the blade body.
8. A method as recited in claim 1, further comprising: positioning
the blade body on the die base, wherein the die base opposes the
plunger across the blade body along a longitudinal axis.
9. A method as recited in claim 1, further comprising: supporting
the blade body and at least one of the blade sheath and the blade
cover with the die base while pressing the blade body and at least
one of the blade sheath and the blade cover.
10. A method as recited in claim 1, further comprising: applying
pressure to a trailing edge side of the blade body in a chord-wise
direction with a cam mechanism for full engagement of a leading
edge of the blade body within the blade sheath.
11. A method as recited in claim 1, wherein pressing the blade body
together with at least one of the blade sheath and the blade cover
includes moving the plunger along a longitudinal axis toward a
broad side of the blade body.
12. A method as recited in claim 1, wherein pressing the blade body
together with at least one of the blade sheath and the blade cover
includes transferring pressure from a plunger surface to a broad
side of the blade body in a plane normal to the broad side of the
blade body.
13. A method as recited in claim 1, further comprising:
constraining the blade body and the blade sheath with a flexible
stopper proximate a leading edge of the blade body.
14. An airfoil produced by a process comprising: pressing a blade
body together with at least one of a blade sheath and a blade cover
between a plunger and a die base to join the blade body to at least
one of the blade sheath and the blade cover.
15. An airfoil as recited in claim 14, wherein the process further
comprises: transferring heat from at least one of the plunger and
the die base to at least one of the blade body, the blade sheath
and the blade cover to cure an adhesive.
16. An airfoil as recited in claim 15, wherein the process further
comprises: applying an adhesive between a broad side of the blade
body at least one of the blade cover and the blade sheath; and
curing the adhesive with heat transferred from at least one of the
plunger and the die base.
17. An airfoil as recited in claim 15, wherein the process further
comprises: applying an adhesive between a leading edge of the blade
body at least one of the blade cover and the blade sheath; and
curing the adhesive with heat transferred from at least one of the
plunger and the die base.
18. An airfoil as recited in claim 14, wherein the process further
comprises: positioning a compliant layer between a broad side of
the blade body and the plunger, wherein the compliant layer is
configured to substantially equalize the distribution of pressure
applied by the plunger across the broad side of the blade body.
19. An airfoil as recited in claim 14, wherein the process further
comprises: positioning a compliant layer between a broad side of
the blade body and the die base, wherein the compliant layer is
configured to substantially equalize the distribution of pressure
across the broad side of the blade body.
20. An airfoil as recited in claim 14, wherein the process further
comprises: applying pressure to a trailing edge side of the blade
body in a chord-wise direction with a cam mechanism for full
engagement of a leading edge of the blade body within the blade
sheath.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority under 35
U.S.C. .sctn.119(e) to U.S. Provisional Application No: 61/923,265,
filed Jan. 3, 2014, which is incorporated herein by reference in
its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present disclosure relates to manufacturing aerospace
components, and more particularly to assembling airfoils, such as
those used in gas turbine engines.
[0004] 2. Description of Related Art
[0005] Some aerospace components, such as a fan blade body and a
blade sheath and/or a blade cover, are assembled using an adhesive
to bond the components together. Traditionally, an autoclave has
been used in the manufacturing process to apply pressure and heat
to the components being assembled to cure the adhesive. However,
using an autoclave to bond a blade cover and/or a blade sheath onto
a blade body can be time consuming and not conducive to lean
manufacturing principles such as one-piece-flow. Further, the
heating rate can be limited due to the fact that the heat transfer
mechanism is based on convection of a gas. Generally, a vacuum bag
is used to act as a membrane to allow the autoclave pressure to act
on the part being cured. Vacuum bagging is typically a manual
operation and the bagging materials are often disposed of after
each use.
[0006] Such conventional methods and systems have generally been
considered satisfactory for their intended purpose. However, there
is still a need in the art for improved systems and methods for
manufacturing aerospace components. The present disclosure provides
a solution for these problems.
SUMMARY OF THE INVENTION
[0007] A method for assembling an airfoil includes pressing a blade
body together with at least one of a blade sheath and a blade cover
between a plunger and a die base to join the blade body to the
blade sheath and/or the blade cover.
[0008] The method can include transferring heat from the plunger
and/or the die base to the components being assembled, e.g. the
blade body, the blade sheath, the blade cover, and/or foam
segments, to cure an adhesive. Transferring heat from the plunger
and/or the die base can include transferring heat through
conduction. The method can also include applying an adhesive
between a broad side of the blade body and at least one of the
blade cover and the blade sheath. The method can also include
applying an adhesive between a leading edge of the blade body and
the blade cover and/or the blade sheath. The method can also
include applying the adhesive between foam segments and respective
cavities formed in the blade body. The method can include curing
the adhesive with heat transferred from the plunger and/or the die
base.
[0009] In another aspect, the method can include positioning a
compliant layer between a broad side of the blade body and the
plunger and/or the die base. The compliant layer can be configured
to substantially equalize the distribution of pressure applied by
the plunger and/or the die base across the broad side of the blade
body. The method can also include positioning the blade body on the
die base. The die base can oppose the plunger across the blade body
along a longitudinal axis. It is further contemplated that the
method can include supporting the blade body and at least one of
the blade sheath and the blade cover with the die base while
pressing the blade body and at least one of the blade sheath and
the blade cover.
[0010] The method can also include applying pressure to a trailing
edge side of the blade body in a chord-wise direction with a cam
mechanism for full engagement of a leading edge of the blade body
within the blade sheath. In addition, pressing the blade body
together with the blade sheath and/or the blade cover can include
moving the plunger along a longitudinal axis toward a broad side of
the blade body. Pressing the blade body together with at least one
of the blade sheath and the blade cover can also include
transferring pressure from a plunger surface to a broad side of the
blade body in a plane normal to the broad side of the blade body.
The method can also include constraining the blade body and the
blade sheath with a flexible stopper proximate a leading edge of
the blade body.
[0011] An airfoil produced by a process as described above,
including a blade body and at least one of a blade sheath and a
blade cover.
[0012] These and other features of the systems and methods of the
subject disclosure will become more readily apparent to those
skilled in the art from the following detailed description of the
embodiments taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] So that those skilled in the art to which the subject
disclosure appertains will readily understand how to make and use
the devices and methods of the subject disclosure without undue
experimentation, embodiments thereof will be described in detail
herein below with reference to certain figures, wherein:
[0014] FIG. 1 is a perspective view of an exemplary embodiment of a
system for assembling a fan blade in accordance with the present
disclosure, showing the plunger and the die base in a platen
press;
[0015] FIG. 2 is an exploded perspective view of an exemplary
embodiment of a fan blade assembled in accordance with the present
disclosure, showing the blade body, blade cover and blade sheath;
and
[0016] FIG. 3 is a cross-sectional side elevation view of the
system of FIG. 1 with the fan blade of FIG. 2, showing the plunger
being pressed downward along the longitudinal axis toward the fan
blade to bond the blade cover and blade sheath to the blade
body.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0017] Reference will now be made to the drawings wherein like
reference numerals identify similar structural features or aspects
of the subject disclosure. For purposes of explanation and
illustration, and not limitation, a partial view of an exemplary
embodiment of a system for assembling an airfoil constructed in
accordance with the disclosure is shown in FIG. 1 and is designated
generally by reference character 100. Other embodiments of systems
for assembling airfoils in accordance with the disclosure, or
aspects thereof, are provided in FIGS. 2-3, as will be described.
The systems and methods described herein can be used to improve
bonding between the blade body and the blade sheath and/or blade
body and consistency in manufacturing.
[0018] As shown in FIG. 1, a system 100 for assembling a fan blade
102 includes a plunger 104, and a die base 106. Die base 106 and
plunger 104 include integral heating elements 105, shown
schematically, such as electrical, steam or oil heating elements.
Plunger 104 and die base 106 are substantially aligned with one
another along a longitudinal axis A, with plunger 104 disposed
above die base 106 along longitudinal axis A in a first position.
Those skilled in the art will readily appreciate that die base 106
and plunger 104 can be contoured to match the contours of fan blade
102, described below. System 100 is disposed within a platen press
101.
[0019] Now with reference to FIG. 2, fan blade 102 being assembled
within system 100 includes a blade body 114, blade cover 116 and a
blade sheath 118. Fan blade 102 also includes foam segments 132
disposed within respective cavities 130 formed in blade body 114. A
method for assembling fan blade 102 includes pressing blade body
104 together with blade sheath 118 and blade cover 116 between
plunger 104 and die base 106, described above, to join blade body
114 and blade sheath 118 and blade cover 116 together. Those
skilled in the art will readily appreciate that the force applied
to blade body 114, blade cover 116 and/or blade sheath 118 can be
calculated by multiplying the projected surface area of a broad
side 122 of blade body 114 and a desired bonding pressure. The
method includes applying an adhesive 120 between broad side 122 of
blade body 114 and blade cover 116, and a leading edge 124 of blade
body 114 and blade sheath 118. The method also includes applying
adhesive 120 between foam segments 132 and respective cavities 130
formed in blade body 114.
[0020] As shown in FIG. 3, system 100 also includes compliant
layers 108, a cam mechanism 110, and a flexible stopper 112. Those
skilled in the art will readily appreciate that compliant layers
108 can be made from any suitable conformable material, such as
silicone, other rubber material, or the like. One compliant layer
108 is positioned between a first broad side 122 of blade body 114,
including blade cover 116 and at least a portion of blade sheath
118, and die base 106. A second compliant layer 108 is positioned
between a second broad side 122 of blade body 114, including at
least a portion of blade sheath 118, and die base 106. Compliant
layers 108 are configured to substantially equalize the
distribution of pressure applied by plunger 104 and die base 106
across broad sides 122 of blade body 114.
[0021] Those skilled in the art will readily appreciate that the
hydrostatic-like pressure application enabled by compliant layers
108 results in high quality bond-lines between components of fan
blade 102, e.g. blade body 114, blade cover 116 and blade sheath
118. The even distribution of pressure tends to reduce local
pressure discontinuities during assembly that can otherwise be
caused by potential variations between different fan blades 102.
Those having skill in the art will readily appreciate that
compliant layers 108 can be positioned on fan blade 102 components
before they are placed onto die base 106 or compliant layers 108
can already be positioned on die base 106 and/or plunger 104.
[0022] With continued reference to FIG. 3, the method includes
positioning blade body 114 with cover 116 and blade sheath 118 on
die base 106, i.e. prior to applying plunger 104. The method
optionally includes applying pressure with cam mechanism 110 to a
trailing edge side 126 of blade body 114 in a chord-wise direction
for full engagement of leading edge 124 of blade body 114 within
blade sheath 118. Those skilled in the art will readily appreciate
that this substantially ensures proper sheath placement without
complicated tooling as used in traditional methods of assembling
fan blades.
[0023] As shown in FIGS. 1 and 3, pressing blade body 114 together
with blade sheath 118 and blade cover 116 includes moving plunger
104 along longitudinal axis A, out of the first position shown in
FIG. 1, toward a first broad side 122 of blade body 114, to a
second position, shown in FIG. 3. Pressing blade body 114 together
with blade sheath 118 and/or blade cover 116 also includes
transferring pressure, e.g. applying a load, from a plunger surface
128 to first broad side 122 of blade body 114 in a plane
substantially normal to first broad side 122 of blade body 114. Die
base 106 supports blade body 114, blade cover 116 and blade sheath
118 during the pressing of blade body 114 and blade sheath 118 and
blade cover 116. The method also includes constraining blade body
114 and blade sheath 118 with a flexible stopper 112 proximate
leading edge 124 of blade body 114. While plunger 104 is shown and
described as moving downward along longitudinal axis A, those
skilled in the art will readily appreciate that die base 106 can
also move along longitudinal axis A upward toward plunger 104.
[0024] The method also includes transferring heat from plunger 104
and die base 106 to blade body 114, blade sheath 118 and blade
cover 116 to cure adhesive 120, as discussed above. Those skilled
in the art will readily appreciate that transferring heat from
plunger 104 and die base 106 to fan blade 102 can include
transferring heat through conduction, enabling faster heat transfer
increases or decreases resulting in increased control over the heat
transfer as compared with traditional methods of assembly. Further,
it is contemplated that plunger 104 and die base 106 can be kept at
a temperature above ambient temperature in order to reduce heat-up
time, as compared with traditional methods of assembly. Those
skilled in the art will readily appreciate that both the conductive
heating and the ability to keep plunger 104 and die base 106 at an
elevated temperature can result in reduced manufacturing cycle time
as compared with traditional methods of assembly.
[0025] Those skilled in the art will also readily appreciate that
that there can be more flexibility in manufacturing due to the
one-piece manufacturing flow facilitated by the platen press as
opposed to batch processing used in traditional methods of
assembly. Further, those skilled in the art will readily appreciate
that there is no required nitrogen source like that typically found
in traditional assembly methods such as autoclaves.
[0026] While shown and described in the exemplary context of fan
blades for gas turbine engines, those skilled in the art will
readily appreciate that the systems and methods described herein
can be used on any other suitable components without departing from
the scope of this disclosure. For example, the embodiments
described herein can readily be applied to other bonded airfoil
assemblies, such as, inlet guide vanes, or the like.
[0027] The methods and systems of the present disclosure, as
described above and shown in the drawings, provide for improved
methods for airfoil assembly. While the apparatus and methods of
the subject disclosure have been shown and described with reference
to preferred embodiments, those skilled in the art will readily
appreciate that changes and/or modifications may be made thereto
without departing from the spirit and scope of the subject
disclosure.
* * * * *